Alignment system and method thereof

ABSTRACT

An alignment system for aligning components includes a first component, a second component, upstanding, elongated tabs connected to at least one of the components, each elongated tab having a tab wall, and deformable elongated tab apertures formed in at least one of the components, each deformable tab aperture comprising opposing deformable aperture walls. The apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the elongated tabs such that each elongated tab is receivable into a respective aperture and each tab has a width larger than a cross-sectional width of its respective aperture measured in a same direction. Each aperture is configured to elastically deform upon disposition of each elongated tab into its respective tab aperture at an interface between the tab wall and the aperture wall.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims priority to U.S. Provisional PatentApplication Ser. No. 61/682,597, filed Aug. 13, 2012, which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The subject invention relates to an alignment system and method thereof,and more particularly to location features for alignment and attachmentof components during a mating operation.

BACKGROUND

Currently, components which are to be mated together in a manufacturingprocess are mutually located with respect to each other by 2-way and/or4-way male alignment features, typically upstanding bosses, which arereceived into corresponding female alignment features, typicallyapertures in the form of holes or slots. There is a clearance betweenthe male alignment features and their respective female alignmentfeatures which is predetermined to match anticipated size and positionalvariation tolerances of the male and female alignment features as aresult of manufacturing (or fabrication) variances. As a result, therecan occur significant positional variation as between the mated firstand second components which contributes to the presence of undesirablylarge and varying gaps and otherwise poor fit therebetween. Accordingly,it is desirable to provide an improved alignment system and method forprecisely aligning components.

SUMMARY OF THE INVENTION

In one exemplary embodiment of the invention, an alignment system foraligning components to each other is disclosed. The system includes afirst component and a second component. The system also includes aplurality of upstanding, elongated tabs connected to at least one of thefirst and second components, each elongated tab having a tab wall. Thesystem further includes a plurality of deformable elongated tabapertures formed in at least one of the first and second components,each deformable tab aperture comprising opposing deformable aperturewalls; wherein the plurality of apertures are geometrically distributedin coordinated relationship to a geometrical distribution of theplurality of elongated tabs such that each elongated tab is receivableinto a respective aperture and each tab has a width larger than across-sectional width of its respective aperture measured in a samedirection, and, wherein each aperture is configured to elasticallydeform upon disposition of each tab into each respective aperture at aninterface between the tab wall of each tab and the aperture wall of eachrespective aperture.

In another exemplary embodiment of the invention, a method for preciselyaligning components of a motor vehicle during a mating operation isdisclosed. The method includes providing a first vehicle component. Themethod also includes providing a second vehicle component, whereineither of the first and second vehicle components are provided with aplurality of upstanding elongated tabs and a plurality of deformableelongated apertures formed therein, wherein the plurality of elongatedapertures are geometrically distributed in coordinated relationship to ageometrical distribution of the plurality of elongated tabs such thateach elongated tab is matingly engageable into a respective elongatedaperture and each tab has a width larger than a cross-sectional width ofits respective aperture measured in a same direction. The method alsoincludes mating the first vehicle component to the second vehiclecomponent by pressing the components together, wherein during pressingthe first vehicle component is aligned to the second vehicle componentby each elongated tab being received into its respective deformableelongated aperture. The method further includes elastically deformingopposing deformable walls of each of the deformable apertures upondisposition of each tab into each respective aperture at an interfacebetween a tab wall of each tab and an aperture wall of each respectiveaperture, wherein elastic deformation of the deformable apertures occursover the plurality of deformable apertures such that upon mating, aprecise location of the first vehicle component to the second vehiclecomponent is realized.

The above features and advantages and other features and advantages ofthe invention are readily apparent from the following detaileddescription of the invention when taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only,in the following detailed description of embodiments, the detaileddescription referring to the drawings in which:

FIG. 1 is a perspective view of one embodiment of an alignment systemand component assembly incorporating the same as disclosed herein;

FIG. 2 is a partially disassembled perspective view of the system andassembly of FIG. 1;

FIG. 3 is a partially disassembled perspective view of the system andassembly of FIG. 1, further comprising a third component;

FIG. 4 is a perspective view of the system and assembly of FIG. 3 in anassembled condition, wherein the components have been aligned accordingto the method disclosed herein;

FIG. 5. is a cross-sectional view of a tab and aperture of FIG. 4; and

FIG. 6 is a flow chart of a method for precisely aligning components ofa motor vehicle during a mating operation as disclosed herein.

DESCRIPTION OF THE EMBODIMENTS

The following description is merely exemplary in nature and is notintended to limit the present disclosure, its application or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

In accordance with an exemplary embodiment of the invention, a thintri-layer door assembly utilizing deformable elastic averaging featuresfor precision alignment is disclosed. This embodiment disposes an innercomponent between two mating outer components to hold the innercomponent and also utilizes deformable elastic averaging features forprecision alignment comprising deformable fixed-fixed beams andinterfacing tabs to precisely locate mating vehicle components. Thisapproach may be used to reduce or eliminate the need for secondaryattachments (e.g. heat staking) to hold the inner component in positionwith regard to one of the outer components during their assembly.

The embodiment uses elongated (e.g. rectangular) tabs mating withdeformable elongated apertures to locate components to each other. Thewidth of each elongated tab is larger than the width of the matingelongated aperture. As the components are assembled opposing deformablewalls of the elongated apertures deform elastically. The deformablewalls comprise fixed beam portions of the respective component. Thiscreates an interference condition that eliminates the variationassociated with the clearances inherent in 2-way/4-way locating schemes.Furthermore, the over constrained interface will flex the fixed-fixedbeam sections on each side of the mating apertures to a position thataverages each aperture's individual positional error. This will resultin part-to-part misalignment equal to each of the elongated tabspositional variation X 1/√N, where N is the number of constraints. Thedeformation of the fixed-fixed beam sections serves to align and stiffenthe interface.

Referring to the Figures, and more particularly FIGS. 1, 2 and 5, analignment system 10 for aligning components to each other is disclosed.The system includes a first component 20 and a second component 40. Thesystem 10 also includes a plurality of upstanding, elongated tabs 22connected to at least one of the first component 20 and second component40, each elongated tab having a tab wall 24. The system further includesa plurality of deformable elongated tab apertures 42 formed in at leastone of the first component 20 and second component 40, each deformabletab aperture 42 comprising opposing deformable aperture walls 44;wherein the plurality of apertures 42 are geometrically distributed incoordinated relationship to a geometrical distribution of the pluralityof elongated tabs 22 such that each elongated tab 22 is receivable intoa respective aperture 42, and wherein when each elongated tab 22 isreceived into its respective tab aperture 42 an elastic deformationoccurs at an interface between the tab wall 24 and the aperture wall 44,wherein the elastic deformation is responsive to each tab wall having awidth larger than a cross-sectional width of its respective aperture 42;and wherein the elastic deformation is elastically averaged over theplurality of deformable aperture walls 44 such that the first component20 is precisely located relative to the second component 40. The elasticdeformation of the aperture walls 44 elastically averages positionalerrors of the tabs 22 relative to the apertures 42. In other words, gapsthat would otherwise be present due to positional errors associated withportions or segments of the tabs 22 and apertures 42 are reduced oreliminated by offsetting the gaps with an over-constrained conditionalong other portions or segments of the tabs 22 and apertures 42. Theprinciples of elastic averaging are described in detail in commonlyowned, co-pending U.S. patent application Ser. No. 13/187,675, thedisclosure of which is incorporated by reference herein in its entirety.

The alignment system 10 may include deformable apertures 42 wherein eachof the deformable aperture walls 44 comprises a deformable fixed beam46. In one embodiment, the deformable fixed beams 46 are defined byelongated beam apertures 48 formed proximate the deformable aperturewalls 44. In an embodiment, the elongated beam aperture 48 has a length(L₂) that is greater than a length (L₁) of the tab aperture 42. Inanother embodiment, the elongated beam aperture 48 extends beyond afirst end 50 and a second end 52 of the tab aperture 42. In oneembodiment, the deformable fixed beam 46 has a predetermined beam width(W_(a)), and the predetermined beam width is selected to obtain apredetermined compliance characteristic of the deformable fixed beam 46.The beam widths W_(a) may be the same or different, depending on thepredetermined compliance characteristics required for each beam 46.

In another embodiment, the deformable fixed beam 46 is defined by a freesurface 54 of the respective component on which it is formed. In thisembodiment, the deformable fixed beam 46 also has a predetermined beamwidth (W_(c)), which may be the same or different than the beam widthW_(a) depending on the predetermined compliance characteristic requiredfor each beam. The beam widths W_(c) may be the same or different,depending on the predetermined compliance characteristics required foreach beam. The predetermined beam width W_(a) is selected to obtain apredetermined compliance characteristic of the deformable fixed beam 46.

In one embodiment, the plurality of elongated tabs 22 each have a tabwall axis 26 and a first portion of the plurality of elongated tabs 22have tab wall axes 26 that are not-parallel to the tab wall axes 26 of asecond portion of the plurality of elongated tabs 22. In anotherembodiment, the first portion of elongated tabs 22 have tab wall axes 26that are substantially orthogonal to the tab wall axes of the secondportion of elongated tabs.

In one embodiment, the plurality of elongated tabs 22 each have abeveled tab edge 28 proximate a top end 30 of the tab. In anotherembodiment, each of the plurality of elongated tab apertures 42 has abeveled aperture edge 56 proximate an entrance opening 58 of the tabaperture 42.

Referring now to FIGS. 1-5, in one embodiment, the alignment system 10further includes an assembly 60 of the first component 20 and the secondcomponent 40, wherein each elongated tab 22 is disposed in thecorresponding elongated tab aperture 42 and deforms the deformableaperture walls 44 thereof. In this embodiment (FIG. 1), each elongatedtab 22 has a top end 30 that projects above a top edge 62 of therespective aperture 42. In another embodiment, the alignment system 10may also include a third component 80, such as a door open and closuremechanism, which is attached to the assembly having a surface 82disposed proximate the top ends 30 of the elongated tabs 22, the surface82 having a plurality of recessed pockets 84 disposed therein that areconfigured to receive the top ends 30 of the elongated tabs 22. Any orall of the components may comprise a surface or surfaces having a classA finish. The alignment system 10 thus provides a system for desiredalignment of the first component 20, second component 40, and thirdcomponent 80 while also providing a compact and space efficient assemblyof these components. In the embodiment of FIGS. 1-5, for example, theassembly has a maximum thickness that is less than the maximumthicknesses of the individual component parts 20, 40, 80. That is, thecomponents are nested within one another to provide a compact assemblywhile at the same time providing for precise alignment of the componentswith respect to one another.

In one embodiment, the system 10 may be used to assemble an assembly 60that comprises a motor vehicle assembly, and more particularly a doorassembly for a motor vehicle.

Any suitable elastically deformable material may be used for the firstcomponent 20 and elongated tabs 22 or the second component 40 and fixedbeams 46 or the third component 80, for example, particularly thosematerials that are elastically deformable when formed into the featuresdescribed herein. This includes various metals, polymers, ceramics,inorganic materials or glasses, or composites of any of theaforementioned materials, or any other combinations thereof. Manycomposite materials are envisioned, including various filled polymers,including glass, ceramic, metal and inorganic material filled polymers,particularly glass, metal, ceramic, inorganic or carbon fiber filledpolymers. Any suitable filler morphology may be employed, including allshapes and sizes of particulates or fibers. More particularly anysuitable type of fiber may be used, including continuous anddiscontinuous fibers, woven and unwoven cloths, felts or tows, or acombination thereof. Any suitable metal may be used, including variousgrades and alloys of steel, cast iron, aluminum, magnesium or titanium,or composites thereof, or any other combinations thereof. Polymers mayinclude both thermoplastic polymers or thermoset polymers, or compositesthereof, or any other combinations thereof, including a wide variety ofco-polymers and polymer blends. In one embodiment, a preferred plasticmaterial is one having elastic properties so as to deform elasticallywithout fracture, as for example, a material comprising an acrylonitrilebutadiene styrene (ABS) polymer, and more particularly a polycarbonateABS polymer blend (PC/ABS). The material may be in any form and formedor manufactured by any suitable process, including stamped or formedmetal, composite or other sheets, forgings, extruded parts, pressedparts, castings, or molded parts and the like, to include the deformablefeatures described herein. The elongated tabs 22 may be formed in anysuitable manner. They may be integrally formed or manufactured with thefirst component 20, or they may formed together separately and attachedto the first component, or they may both be formed entirely separatelyand attached to the first component. When formed separately, they may beformed from different materials than those of the first component 20 toprovide a predetermined elastic response characteristic, for example.The material, or materials, may be selected to provide a predeterminedelastic response characteristic of any or all of the first component 20or second component 40 or third component 80, particularly thedeformable fixed beams 46. The predetermined elastic responsecharacteristic may include, for example, a predetermined elasticmodulus.

Referring to FIGS. 2-4, the first component 20 or third component 80 mayalso include elastic tubes 90 and corresponding apertures 92 as part ofthe alignment system 10 and assembly 60 disclosed herein. These elastictubes 90 and corresponding apertures 92 and their use in an alignmentsystem are described in commonly owned, co-pending U.S. patentapplication Ser. No. 13/187,675.

Referring to FIG. 6, in one embodiment, a method 200 for preciselyaligning components of a motor vehicle during a mating operation isdisclosed. The method includes providing 210 a first vehicle component.The method also includes providing 220 a second vehicle component,wherein either of the first and second vehicle components are providedwith a plurality of upstanding elongated tabs and a plurality ofdeformable elongated apertures formed therein, wherein the plurality ofelongated apertures are geometrically distributed in coordinatedrelationship to a geometrical distribution of the plurality of elongatedtabs such that each elongated tab is matingly engageable into arespective elongated aperture. The method also includes mating 230 thefirst vehicle component to the second vehicle component by pressing thecomponents together, wherein during pressing the first vehicle componentis aligned to the second vehicle component by each elongated tab beingreceived into its respective deformable elongated aperture. The methodfurther includes elastically deforming 240 opposing deformable walls ofeach of the deformable apertures. Still further, the method includeselastically averaging 250 the elastic deformation over the plurality ofdeformable apertures such that upon mating, a precise location of thefirst vehicle component to the second vehicle component is realized.

While the invention has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiments disclosed, but that theinvention will include all embodiments falling within the scope of theapplication.

What is claimed is:
 1. An alignment system for aligning components toeach other, comprising: a first component; a second component; aplurality of upstanding, elongated tabs connected to at least one of thefirst and second components, each elongated tab having a tab wall; aplurality of deformable elongated tab apertures formed in at least oneof the first and second components, each deformable tab aperturecomprising opposing deformable aperture walls; wherein the plurality ofapertures are geometrically distributed in coordinated relationship to ageometrical distribution of the plurality of elongated tabs such thateach elongated tab is receivable into a respective aperture and each tabhas a width larger than a cross-sectional width of its respectiveaperture measured in a same direction; wherein each aperture isconfigured to elastically deform upon disposition of each tab into eachrespective aperture at an interface between the tab wall of each tab andthe aperture wall of each respective aperture; an assembly of the firstcomponent and the second component, wherein each elongated tab isdisposed in the corresponding elongated tab aperture and deforming thedeformable aperture walls thereof, wherein each elongated tab has a topend that projects above a top edge of the respective aperture; and athird component that is attached to the assembly having a surfacedisposed proximate the top ends of the elongated tabs, the surfacehaving a plurality of recessed pockets disposed therein that areconfigured to receive the top ends of the elongated tabs.
 2. Thealignment system of claim 1, wherein each of the deformable aperturewalls comprises a deformable fixed beam.
 3. The alignment system ofclaim 2, wherein the deformable fixed beam is defined by an elongatedbeam aperture formed proximate the deformable aperture wall.
 4. Thealignment system of claim 3, wherein the elongated beam aperture has alength that is greater than a length of the tab aperture.
 5. Thealignment system of claim 4, wherein the elongated beam aperture extendsbeyond a first end and a second end of the tab aperture.
 6. Thealignment system of claim 2, wherein the deformable fixed beam has apredetermined beam width.
 7. The alignment system of claim 6, whereinthe predetermined beam width is selected to obtain a predeterminedcompliance characteristic of the deformable fixed beam.
 8. The alignmentsystem of claim 2, wherein the deformable fixed beam is defined by afree surface of the respective component on which it is formed.
 9. Thealignment system of claim 8, wherein the deformable fixed beam has apredetermined beam width.
 10. The alignment system of claim 9, whereinthe predetermined beam width is selected to obtain a predeterminedcompliance characteristic of the deformable fixed beam.
 11. Thealignment system of claim 1, wherein the plurality of elongated tabseach have a tab wall axis and a first portion of the plurality ofelongated tabs have tab wall axes that are not-parallel to the tab wallaxes of a second portion of the plurality of elongated tabs.
 12. Thealignment system of claim 11, wherein the first portion of the elongatedtabs have tab wall axes that are substantially orthogonal to the tabwall axes of the second portion of elongated tabs.
 13. The alignmentsystem of claim 1, wherein the plurality of elongated tabs each have abeveled tab edge proximate a top end of the tab.
 14. The alignmentsystem of claim 1, wherein the plurality of elongated tab apertures havea beveled aperture edge proximate an entrance opening of the tabaperture.
 15. The alignment system of claim 1 wherein the assemblycomprises a motor vehicle assembly.
 16. The alignment system of claim15, wherein the motor vehicle assembly comprises a door assembly.